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The Carcass

From 1996 Ford Bronco “Carcass Stripped”, documented by Steve83.

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1996 Ford Bronco - Owww... Odo 299,062.2mi 1996 Ford Bronco - This is what the PO did to it shortly after buying it - an open storm drain in a busy street caused him to hit a large power pole. The pole… 1996 Ford Bronco - Since he had no use for it, and his replacement needs some work, he's trading me this carcass for the labor. 1996 Ford Bronco - I'm not sure I'm getting such a good deal... 1996 Ford Bronco - The carcass is ready to roll gently down the hill onto the trailer. 1996 Ford Bronco - Loaded & ready to roll! 1996 Ford Bronco - Some moron in a Mercedes assumed he could cut me off, and actually got offended that I didn't let him. He must have been blind to think tha… 1996 Ford Bronco - I hope to have it stripped in a couple of weeks. 1996 Ford Bronco - The WP hub shouldn't be this close to the housing... 1996 Ford Bronco - ...and the back of the crank pulley should be flat. 1996 Ford Bronco - Well, THERE'S your problem! Fortunately, the oil came out clean, so virtually no coolant went into the crankcase before the engine stopped.… 1996 Ford Bronco - This shouldn't be too hard to extract. I'll soak it with penetrant until I'm ready to pull the intake for new gaskets. [url=https://www.sup… 1996 Ford Bronco - In addition to the folded frame & punctured timing cover, the axle is twisted due to the front crossmember being mashed back. The driveshaf… 1996 Ford Bronco - Misfire sensor & tone ring behind the harmonic balancer ('96-only) on a 5.8L (5.0L same; 4.9L similar). 1996 Ford Bronco - All the safety features worked: seat belts, airbag, and even the telescoping steering column, which slid forward off its rear (cast-Aluminu… 1996 Ford Bronco - The column is so far forward that the shifter wouldn't go into park. 1996 Ford Bronco - After several rounds of PurplePower, Dawn, & water hose, the carpets are clean enough to be vacuumed so they can go into the replacement Br… 1996 Ford Bronco - These are most of the tags on the truck. IF THE IMAGE IS TOO SMALL, click it. The one I forgot to label below the frame & above the camper… 1996 Ford Bronco - Instrument cluster tag (made by Altec) The top line of text abbreviations means: RPO - regular production option (tachometer & gauges) MPH… 1996 Ford Bronco - This dipstick is substantially longer than the one on my '93, making it much easier to reach. But the joint in the tube doesn't appear to b… 1996 Ford Bronco - This FDM appears to have been replaced after 2003 (probably under the recall), and then the reservoir with pump motor inside was replaced l… 1996 Ford Bronco - Rear axle tag S838M (Sterling axle plant; internal coding) 3 55 88 5L21 (3.55 ratio, open diff; 8.8" axle; 1995 December 21) Odo 299,062.2mi 1996 Ford Bronco - Some friends helped me flip the body off the frame so I could dismantle the chassis. 1996 Ford Bronco - Some friends helped me flip the body off the frame so I could dismantle the chassis. [url=https://www.supermotors.net/registry/media/113432… 1996 Ford Bronco - The impact was so hard that these mounts (#2 L&RHS) bent forward, evidenced by the wider gap at the rear (right of picture). 1996 Ford Bronco - The impact was so hard that this mount (#3 LHS) bent forward, evidenced by the spalled paint near the frame at the front & rear corners. Co… 1996 Ford Bronco - Engine RHS just after flipping the body off. 1996 Ford Bronco - T-case RHS just after flipping the body off. 1996 Ford Bronco - Tank & axle RHS just after flipping the body off. 1996 Ford Bronco - Engine LHS just after flipping the body off. 1996 Ford Bronco - T-case LHS just after flipping the body off. 1996 Ford Bronco - Tank & axle LHS just after flipping the body off. 1996 Ford Bronco - '96 5.8L Engine Vacuum Harness (no 2ndry air or MAP) [url=https://www.supermotors.net/registry/media/1151310] https://www.supermotors.net/g… 1996 Ford Bronco - '96 5.8L Engine Wiring Harness 1996 Ford Bronco - Chassis front just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133840] https://www.supermotors.net/get… 1996 Ford Bronco - Engine RHS just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133861] https://www.supermotors.net/getfil… 1996 Ford Bronco - Trans & t-case RHS just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133862] https://www.supermotors.ne… 1996 Ford Bronco - Tank & axle RHS just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133863] https://www.supermotors.net/g… 1996 Ford Bronco - Engine LHS just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133865] https://www.supermotors.net/getfil… 1996 Ford Bronco - Trans & t-case LHS just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133866] https://www.supermotors.ne… 1996 Ford Bronco - Tank & axle LHS just after pressure-washing. Before: [url=https://www.supermotors.net/registry/media/1133867] https://www.supermotors.net/g… 1996 Ford Bronco - Emptying the tank into mine, using an old fuel pump (probably from a Crown Vic tank), the battery pack from my cheapo cordless impact, & so… 1996 Ford Bronco - It's getting close... 1996 Ford Bronco - I couldn't hammer this body mount sleeve apart, so I soaked it for a few days and then hammered it together. ...a little too hard, I guess. 1996 Ford Bronco - The rear main & bore plugs look OK, so I'll probably leave the seal alone. I assume that's the block SN just below the LHS head, but it's t… 1996 Ford Bronco - After the last of the oil drains out, I'll pull the manifolds, timing cover, & pan; and paint everything like I did the '93's engine. 1996 Ford Bronco - The exhaust manifold has to come off to get the broken bolt out, so I'll pull both & sandblast/paint them like the '93's engine. [url=https… 1996 Ford Bronco - With the front suspension unloaded, I was able to flip the exhaust to work it over the axle, and slide it out the front of the frame. The b… 1996 Ford Bronco - The L axle beam is substantially bent, but the R looks OK. 1996 Ford Bronco - I had to use my thinnest open wrench to back up the exhaust shield nuts. 2 of the bolts were broken. [url=https://www.supermotors.net/regis… 1996 Ford Bronco - Distributor tag & drive gear for roller cam. Eventually, I taped off the tag & gear, sandblasted the Aluminum, and clearcoated it before in… 1996 Ford Bronco - The missing chunk of timing cover was resting on the splash shelf. The milk in the oil pan is just from the pressure washing. See the NEXT… 1996 Ford Bronco - I was amazed to find these original valve cover gaskets are steel, with just a thin inner lip of rubber. They adhered VERY well to the cove… 1996 Ford Bronco - The chain has barely any more slack than a new one would. Probably less than 2 degrees. Odo 299,062.2mi 1996 Ford Bronco - The oil pump pickup was clear, but it's also clean now. The oil pan gasket appears to be reusable. But there are still 2 broken bolts in ea… 1996 Ford Bronco - I cut these bolt heads off so there would be more to work with when I try to extract them. But first, they'll soak in penetrant for a week… 1996 Ford Bronco - After spraying this [url=https://www.amazon.com/dp/B000C11GBE/]Dorman 635-100 with DupliColor DE1650, I put some [url=https://www.amazon.co… 1996 Ford Bronco - Drilling a hole into this blind boss to let some penetrating oil soak for a few days paid off. This bolt was the easiest (of the 8 that bro… 1996 Ford Bronco - I've been procrastinating, but today I went after these intake bolts. They've been soaking in penetrant for about a week, from both sides,… 1996 Ford Bronco - I drilled through, to check that the hole was centered & aligned, and stepped up 1/32" at a time to 1/4", which I drilled left-handed. See… 1996 Ford Bronco - Unfortunately, the bolt still didn't unscrew, but it was so thin that most of the bolt thread peeled out of the head's threads. See the PRE… 1996 Ford Bronco - I chased the remaining bolt thread & corrosion out with a tap, and cleaned the pocket at the top. See the PREVious & NEXT few pics... 1996 Ford Bronco - The driver's side bolt sheared at an angle, making it harder to find center. I had to dig the corrosion out of the pocket first, die-grind… 1996 Ford Bronco - The hole was very slightly off-center near the bottom, but not enough to damage the head. The bolt will still hold well. See the PREVious f… 1996 Ford Bronco - After a few days soaking with penetrant, I punched, drilled, & extracted the 2 ex.man. bolts that had sheared. These [url=https://www.amazo… 1996 Ford Bronco - These '96 water pump bolts are slightly different from the '93's. The pump is a new Ford F3TZ-8501-C , aka MotorCraft PW254 . [url=https://… 1996 Ford Bronco - Original high-temperature studs & nuts aren't available now, so I'll be using these [url=https://www.amazon.com/dp/B001FKEXV6/]Dorman 03135… 1996 Ford Bronco - New [url=https://www.amazon.com/dp/B001088OIQ/]Motorcraft SP-501 plugs, of course. These are ASF-32P, as specified on the VECI label. [url=… 1996 Ford Bronco - I didn't realize this grommet would be chinese when I ordered it, but my local Ford doesn't sell it (possibly E7AZ-6A892-A). 0.715 In. ID x… 1996 Ford Bronco - These have been soaking for a couple of months, but they were still tight. 2 came out this way... See the NEXT pic. 1996 Ford Bronco - Even after a couple months in PB Blaster, one sheared & required drilling before going out forward. 1996 Ford Bronco - The fuel rail is pretty scruffy, so... [url=https://www.supermotors.net/registry/media/1137772] https://www.supermotors.net/getfile/1137772… 1996 Ford Bronco - I polished the chrome & stainless (FPR) with fine steel wool, and clearcoated the chrome with DE1636 . I rinsed the injectors with carb cle… 1996 Ford Bronco - After sandblasting, planing, painting (Rustoleum High Heat Silver), & new flange hardware (cheapo aftermarket because there were no others… 1996 Ford Bronco - Eventually, I got all the exhaust manifold bolts in (with nickel anti-seize) & torqued. Then I added the heat shields & accessory nuts. [ur… 1996 Ford Bronco - Eventually, I got all the bolts in (with nickel anti-seize) & torqued. Then I added the heat shields & accessory nuts. [url=https://www.sup… 1996 Ford Bronco - After mounting the plenum, the throttle body (carefully sandblasted & clearcoated) went on with a new gasket. 1996 Ford Bronco - Original '96 5.8L IAC (F4TE-9F715-AA) built 1996 Feb. 07 3rd shift 1st line 1996 Ford Bronco - Original '96 5.8L MAF sensor (F5UF-12B579-BA, built 1996 Feb.19 - 2nd shift) & venturi One of the screw heads (Tamper Torx 15) is epoxy-fil… 1996 Ford Bronco - Now that my sandblaster is working so well, I finished the accessory brackets, pulleys, & Saginaw. I painted the tensioner's LH-threaded bo… 1996 Ford Bronco - It's a cool rainy day, so I put the exterior wiring harness sections outside, and washed them with PurplePower. I could pressure-wash them,… 1996 Ford Bronco - My new toy is a 660-lb (300 kg) digital hanging scale , which is interesting to use on the larger parts. I never lifted weights, so I didn'… 1996 Ford Bronco - Most of the body tub is going to the scrapyard, on top of most of the frame, and most of the '94 Crown Vic, along with some other metal. Af…